Semiconductor device with a line and method of fabrication thereof

ABSTRACT

A semiconductor device includes an interlayer insulation film, an underlying line provided in the interlayer insulation film, a liner film overlying the interlayer insulation film, an interlayer insulation film overlying the liner film. The underlying line has a lower hole and the liner film and the interlayer insulation film have an upper hole communicating with the lower hole, and the lower hole is larger in diameter than the upper hole. The semiconductor device further includes a conductive film provided at an internal wall surface of the lower hole, a barrier metal provided along an internal wall surface of the upper hole, and a Cu film filling the upper and lower holes. The conductive film contains a substance identical to a substance of the barrier metal. A highly reliable semiconductor device can thus be obtained.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation of and claims the benefit of priority under 35 USC §120 from U.S. Ser. No. 12/730,039, filed Mar. 23, 2010 which is a continuation of U.S. Ser. No. 11/676,962, filed Feb. 20, 2007 which is a continuation of U.S. Ser. No. 11/148,307, filed Jun. 9, 2005, the entire contents of each of which are incorporated herein by reference. U.S. application Ser. No. 11/148,307 claims the benefit of priority under 35 U.S.C. §119 from Japanese Patent Application No. 2005-165252, filed Jun. 6, 2005, and Japanese Patent Application No. 2004-172500, filed Jun. 10, 2004.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to semiconductor devices and methods of fabrication thereof and particularly to highly reliable semiconductor devices and methods of fabrication thereof.

2. Description of the Background Art

As a material for a line for large scale integration circuits (LSIs), aluminum has conventionally been employed. However, as LSIs are increasingly microfabricated and operated more rapidly, aluminum is being replaced with copper (Cu), a material smaller in electrical resistance. Employing Cu as a material for a line for LSIs allows electrical resistance to be reduced and also the line to be microfabricated, and also allows LSIs to operate faster. Cu, however, is diffusible into insulation film. If Cu diffuses into insulation film, the line would be impaired in reliability. Furthermore, Cu reacts with plasma ions very slowly. As such, if etching is employed to form the line, sufficient productivity cannot be achieved.

To address these disadvantages in recent years a Cu line is formed in damascene. If typical damascene is employed to form a Cu line the line is formed as follows:

Initially an underlying line of Cu is covered with a liner film, an interlayer insulation film and an anti-reflection film deposited in layers. Subsequently, resist for forming a via hole is deposited on the anti-reflection film and typical photolithography and etching are employed to provide the interlayer insulation film with the via hole so that the via hole has a bottom has a bottom surface exposing the liner film. The resist for forming the via hole is then removed and thereafter resist for forming a trench is deposited on the anti-reflection film and in the via hole and typical photolithography and etching are employed to provide the interlayer insulation film with a trench. Then the resist for forming the trench and the anti-reflection film are removed and thereafter the liner film exposed at the bottom surface of the via hole is etched to expose the underlying line. Then a Cu oxide film of a surface of the underlying line exposed at the via hole's bottom surface, residue (or polymer) produced in etching the liner film, and the like are removed by performing argon (Ar) sputter etching, annealing in an ambient of hydrogen (H₂), a plasma process, wet-etching, or the like. Then, bather metal is deposited on the via hole and trench's sidewall and bottom surfaces and the interlayer insulation film. Then, a thin Cu film serving as a film that shields plating is deposited on the barrier metal, and plating is employed to deposit a Cu film on the via hole and trench's sidewall and bottom surfaces, and the interlayer insulation film. Then, excessive Cu film and barrier metal on the interlayer insulation film is chemically mechanically polished and thus removed to complete the Cu line.

The Cu line thus obtained, however, is more breakable as voids are caused. More specifically, when high temperature is attained for example in a thermal treatment, an actual environment of use, or the like, thermal stress is caused between the interlayer insulation film and the Cu line. For a conventional Cu line, the underlying line's surface and the via hole's side wall are in contact with each other at a right angle, and a portion at which the underlying line's surface and the Cu line's bottom contact each other tends to experience concentrated thermal stress.

Furthermore in the via hole the Cu line passes a current, which passes through the portion at which the underlying line's surface and the Cu line's bottom contact each other, and flows to the underlying line, which has a larger area in cross section than the via hole. As such, the portion at which the underlying line's surface and the Cu line's bottom contact each other tends to experience a concentrated current.

Thus the portion at which the underlying line's surface and the Cu line's bottom tends to experience concentrated thermal stress and current. As such, the portion provides a point initially causing voids. For a conventional Cu line, the underlying line and the Cu line contact each other in a plane. As such, the lines mutually contact over an insufficient area, and the line is disadvantageously more breakable. Furthermore, between the Cu line and the underlying line there is a disadvantageously large electrical resistance.

To address this, a method of forming a line that allows a Cu line and an underlying line to mutually contact over an increased area is disclosed for example in Japanese Patent Laying-Open No. 2002-064138. As described in the document, the line is formed as follows:

On a first layer line of Cu a copper diffusion preventing insulation film is deposited and thereafter an interlayer insulation film is deposited. Subsequently on the interlayer insulation film a resist film is deposited and used as a mask to expose a surface of the first layer line by anisoptropically etching the interlayer insulation film and the copper diffusion preventing insulation film. Furthermore, the first layer line's exposed surface is further etched to form a contact hole having a bottom deeper than the first layer line's surface. Subsequently a barrier layer is deposited on the interlayer insulation film including the contact hole's interior. Subsequently, a tantalum (Ta) film is deposited on the barrier layer. Subsequently, the Ta film and barrier layer outside the contact hole is chemically mechanically polished and thus removed to form a plug on the first layer line.

In the method disclosed in the publication the interlayer insulation film and the first layer line are etched to form a hole which in turn has a plug introduced therein. As such, the plug has a bottom surface and a partial side surface in contact with the first layer line. More specifically, the plug and the first layer line can mutually contact stereoscopically and hence over an increased area.

Other than the above publication, for example Japanese Patent Laying-Open Nos. 2001-077195, 2000-114261, 07-014836 and 2000-133711 also disclose etching an interlayer insulation film and an underlying line to form a hole which is in turn provided therein with a conductive layer.

As disclosed in Japanese Patent Laying-Open No. 2002-064138, resist remaining in the hole and residue (or polymer) of the copper diffusion preventing insulation film are removed, and this requires that after the interlayer insulation film and the first layer line are etched the hole's interior be washed. However, the hole's interior is washed with a solution having a property dissolving Cu. As such, in the cleaning the hole the first layer liner is wet-etched. This results in the first layer line having a hole larger in diameter than that in the interlayer insulation film. In other words, the first layer line has a hole having an internal wall with a recess. At this recess the barrier layer and the Ta film are hardly deposited (or tend to be discontinuous). As such, the recess provides a point initially causing voids, which tend to increase electrical resistance and render the line more breakable. This results in a semiconductor device impaired in reliability.

SUMMARY OF THE INVENTION

The present invention contemplates a highly reliable semiconductor device and method of publication thereof.

The present semiconductor device includes a first insulation film, a line provided in the first insulation film, a second insulation film provided on the first insulation film, and a third insulation film provided on the second insulation film. The line or the line and the first insulation film has or have a lower hole, and the second insulation film and the third insulation film have an upper hole communicating with the lower hole, and the lower hole is larger in diameter than the upper hole. The semiconductor device further includes a lower conductive film provided at an internal wall surface of the lower hole, an upper conductive film provided along an internal wall surface of the upper hole, and a conductive film containing copper and filling the upper and lower holes. The lower conductive film contains a substance identical to that of the upper conductive film.

The present method of fabricating a semiconductor device includes the steps of: depositing on a first insulation film having a line formed therein a second insulation film and a third insulation film deposited in layers; providing the second and third insulation films with an upper hole reaching the line or the line and the first insulation film; wet-etching an interior of the upper hole to form in the line a lower hole larger in diameter than the upper hole; depositing an upper conductive film covering an inner wall surface of the upper hole and only a bottom of the lower hole; physically etching the upper conductive film present at the bottom of the lower hole to provide a lower conductive film on an inner wall surface of the lower hole; and depositing a conductive film containing copper and filling the upper and lower holes.

In accordance with the present semiconductor device and its fabrication method even if a lower hole is larger in diameter than an upper hole the lower hole can have an internal wall surface with a lower conductive film thereacross. The lower hole can thus be free of significant voids and the semiconductor device can be increased in reliability.

The foregoing and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross section of a structure of a semiconductor device in a first embodiment of the present invention.

FIG. 2 is a cross section for illustrating a first step of a method of fabricating the semiconductor device in the first embodiment of the present invention.

FIGS. 3-10 are cross sections for illustrating in an order of steps of the method of fabricating the semiconductor device in the first embodiment of the present invention.

FIGS. 11 and 12 are cross sections of structures of semiconductor devices in second and third embodiments, respectively, of the present invention.

FIG. 13 is a cross section of a structure in an exemplary variation of the semiconductor device in the first to third embodiments of the present invention.

FIG. 14 is a cross section of a structure of a semiconductor device in a fourth embodiment of the present invention.

FIG. 15 is a simplified cross section of a semiconductor device in a fifth embodiment of the present invention.

FIG. 16 is a simplified cross section of another semiconductor device in the fifth embodiment of the present invention.

FIG. 17 is a simplified cross section of a semiconductor device in a sixth embodiment of the present invention.

FIG. 18 shows a relationship between life and cumulative defective product proportion.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Hereinafter the present invention's embodiments will be described with reference to the drawings.

First Embodiment

As shown in FIG. 1, the present embodiment provides a semiconductor device mainly including an interlayer insulation film 1 serving as a first insulation film, an underlying line 5 serving as a line, a liner film 11 serving as a second insulation film, and an interlayer insulation film 12 serving as a third insulation film. Interlayer insulation film 1 has a groove 2 formed therein, and along the groove's internal wall surface and bottom surface, barrier metals 3 and 4 are deposited in layers, and trench 2 is filled with underlying line 5 deposited on barrier metal 4. Underlying line 5 is covered with liner film 11 and interlayer insulation film 12 deposited on interlayer insulation film 1 in layers. Liner film 11 serves to prevent Cu contained in underlying line 5 from diffusing into interlayer insulation film 12. Furthermore, it also serves as an etching stopper in forming an upper hole 10 described later.

Interlayer insulation film 12 has a trench 14. Furthermore, through the interlayer insulation film 12 trench 14 and liner film 11, upper hole 10 is provided. Furthermore, underlying line 5 is provided with a lower hole 8. Upper hole 10 and lower hole 8 communicate with each other. Lower hole 8 has a hole 6 and a dug portion 7. Hole 6 has a semi-circular cross section. Hole 6 in a vicinity of a boarder between upper and lower holes 10 and 8, i.e., between liner film 11 and underlying line 5, has a diameter d₂ larger than a diameter d₁ of upper hole 10. Hole 6 has a bottom with dug portion 7 forming a portion of lower hole 8. Dug portion 7 has a diameter d₃ smaller than the hole 6 diameter d₂ and the upper hole 10 diameter d₁. Dug portion 7 has a bottom 7 a in the form for example of a cone a hemisphere or the like.

Furthermore in the present embodiment the semiconductor device further includes a conductive film 15 provided across an internal wall surface of lower hole 8 and serving as a lower conductive film, a barrier metal 13 provided along an internal wall surface of upper hole 10 and serving as an upper conductive film, a Cu film 19 filling upper and lower holes 10 and 8, and a barrier metal 17.

Barrier metal 13 is provided along an internal wall surface of trench 14 and that of upper hole 10. Barrier metal 13 interrupts at the boarder between upper and lower holes 10 and 8. In lower hole 8, conductive film 15 is introduced to cover the entire internal wall surface of lower hole 8. Conductive film 15 is not introduced into dug portion 7 at bottom 7 a. Conductive film 15 contains a substance identical to a substance of barrier metal 13 and underlying line 5. Note that while in FIG. 1 conductive film 15 is also provided in trench 14 and upper hole 10 on barrier metal 13, conductive film 15 provided at least across the entire internal wall surface of lower hole 8 suffices. On conductive film 15 in trench 14 and upper and lower holes 10 and 8 barrier metal 17 is deposited and thereon Cu film 19 is deposited to fill trench 14 and upper and lower holes 10 and 8. Note that in the present semiconductor device upper hole 10 has an internal wall surface provided with a layer A (in FIG. 1, barrier metal 13, conductive film 15 and barrier metal 17), and dug portions 7 has an internal wall surface provided with a layer B (in FIG. 1, conductive film 15 and barrier metal 17) and bottom 7 a provided with a layer C (in FIG. 1, barrier metal 17) such that a relationship A≧B≧C is established in thickness or number.

Note that liner film 11 is formed for example of SiCN, SiCO, SiC, or the like. Interlayer insulation film 12 is formed for example of tetra ethyl ortho silicate (TEOS), SiO₂, SiOC, or the like. Barrier metal 3 is formed for example of TaN and barrier metal 4 and 17 is formed for example of Ta. Underlying line 5 is formed for example of Cu. Furthermore, barrier metal 13 is formed of film of at least one type selected from the group consisting of tantalum nitride, tantalum silicide, tantalum carbide, titanium nitride, titanium silicide, titanium carbide, tungsten nitride, tungsten silicide, tungsten carbide, ruthenium (Ru), and ruthenium oxide.

In the present embodiment's semiconductor device, underlying line 5 is etched to form lower hole 8, and conductive films such as Cu film 19, barrier metal 17 and conductive film 15 are provided in lower hole 8. Thus lower hole 3 is internally provided with a conductive film having a bottom surface and a partial side surface in contact with underlying line 5. More specifically, lower hole 8 is internally provided with a conductive film contacting underlying line 5 stereoscopically and hence over an increased area. This can alleviate thermal stress and a current otherwise concentrated at a portion at which a surface of underlying line 5 and a bottom of the conductive film in lower hole 8 contact each other. This can contribute to reduced voids and the line can be less breakable. Furthermore, it can also reduce electrical resistance between Cu film 19 and underlying line 5.

In the present embodiment the semiconductor device is fabricated in a method as will now be described hereinafter.

With reference to FIG. 2, interlayer insulation film 1 is provided therein with groove 2. Then on interlayer insulation film 1 and in groove 2 on an internal wall surface and a bottom surface, chemical vapor deposition (CVD), sputtering or the like is employed to deposit barrier metals 3 and 4 in layers. Then to fill groove 2 and cover interlayer insulation film 1, CVD, plating or the like is employed to deposit a conductive film which will serve as underling line 5. Then, excessive barrier metal 3 and 4 on interlayer insulation film 1, and excessive conductive film are chemically mechanically polished and thus removed. Thus underlying line 5 is provided internal to interlayer insulation film 1. Then, underlying line 5 is covered with liner film 11 deposited on interlayer insulation film 1.

With reference to FIG. 3, on liner film 11 interlayer insulation film 12 and an anti-reflective layer (ARL) 20 are deposited in layers. Then, a patterned resist 25 a is deposited on anti-reflective layer 20 and used as a mask for etching anti-reflective layer 20 and interlayer insulation film 12 to form a hole 10 a, which is a portion of upper hole 10. Hole 10 a has a bottom exposing liner film 11.

With reference to FIG. 4, resist 25 a is removed and thereafter a patterned resist 25 b is provided on interlayer insulation film 12 and in hole 10 a. Then, resist 25 b is used as a mask for etching anti-reflective layer 20 and interlayer insulation film 21 to form trench 14.

With reference to FIG. 5, resist 25 b and anti-reflective layer 20 are removed and thereafter liner film 11 exposed at the bottom of hole 10 a is etched away to provide interlayer insulation film 12 and line film 11 is provided with upper hole 10. Note that liner film 11 may not be completely be removed in forming upper hole 10. Furthermore, liner film 11 is etched such that underlying line 5 exposed at the bottom of upper hole 10 is not etched. Upper hole 10 thus formed has residue of resist 25 b, that (or polymer) of liner film 11 remaining therein. To remove the residues, upper hole 10 then has its interior wet etched. Furthermore, if necessary, in addition to wet etching, sputter-etching using argon (Ar) gas, a helium (He)-Ar gaseous mixture or the like, annealing performed in an ambient containing hydrogen (H2) of several to 100% (for example at 100° C. to 350° C. for 10 to 180 seconds), a (remote) plasma process, or the like may be performed.

Note that wet etching has a nature allowing a substance to be isotropically etched. As such, when upper hole 10 is internally wet-etched, together with the residues, underlying line 5 is also etched and hole 6 having a semi-circular cross section results. Hole 6 in a vicinity of a boarder between liner film 11 and underlying line 5 has diameter d₂ larger than diameter d₁ of upper hole 10. In other words, hole 6 has an internal wall surface removed to be radially outer than that of upper hole 10 (in FIG. 5, in the lateral direction).

With reference to FIG. 6, for example sputtering, CVD or the like is employed to provide a conductive film 13 a, which will serve as barrier metal 13, to cover an inner wall surface of upper hole 10 and only a bottom of hole 6. As has been described previously, hole 6 has an inner wall surface removed to be radially outer than that of upper hole 10 so that the hole has the inner wall surface free of conductive film 13 a. Conductive film 13 a is provided for example by the following method:

Initially a wafer is introduced into a load lock chamber in a CVD apparatus, a sputtering apparatus or similar film deposition apparatus and the chamber is vacuumed.

Then in the vacuum the wafer is heated to a temperature of at least 100° C. and at most 400° C. to remove water or the like on a surface of the wafer. Then at −50° C. to −300° C. conductive film 13 a is deposited to have a thickness of approximately 0.5 nm to 50 nm.

With reference to FIG. 7, conductive film 13 a present at a bottom of hole 6 is physically etched and thus scattered to the hole's internal wall surface to deposit a conductive film 15 a across the entirety of the surface (FIG. 9). Conductive film 15 a contains a substance identical to a substance of conductive film 13 a. Note that conductive film 13 a may be scattered to the trench 14 internal wall surface and upper than interlayer insulation film 12 to provide conductive film 15 a on the trench's internal wall surface and over interlayer insulation film 12.

Conductive film 13 a is physically etched for example by sputter-etching using Ar, resputtering using sputter particles by bias sputter, or the like. Preferably, conductive film 13 a is physically etched under such a condition that the hole 6 bottom is etched at a rate faster than the trench 14 and hole 6 internal wall surfaces are etched. Furthermore, sputtering small in vertical component (or directivity) and the above sputter etching may simultaneously be performed.

With reference to FIG. 8, after conductive film 13 a present at the bottom of hole 6 is completely etched, underlying line 5 present at the bottom of hole 6 is physically etched and thus partially scattered toward the hole 6 internal wall surface to form dug portion 7 at the bottom of hole 6. Conductive film 15 a provided across the entire internal wall surface of hole 6 further contains a substance identical to a substance of underlying line 5. Note that underlying line 5 may partially be scattered to the trench 14 internal wall surface and upper than interlayer insulation film 12 to provide conductive film 15 a on the trench 14 internal wall surface and over interlayer insulation film 12. When conductive film 15 a is provided on the trench 14 internal wall surface and over interlayer insulation film 12, conductive film 13 a serves as barrier metal and prevents Cu contained in conductive film 15 a from diffusing into liner film 11 and interlayer insulation film 12. Preferably, underlying line 5 existing at the bottom of hole 6 is etched at least one fourth or 30 nm in thickness.

With reference to FIG. 9, after the etching, hole 6 having an internal wall surface removed to be radially outer than that of upper hole 10 has its internal wall surface entirely filled with conductive film 15 a. Furthermore, as dug portion 7 is formed by etching through upper hole 10, dug portion 7 has diameter d₃ smaller than diameter d₁ of upper hole 10 and substantially equal to that of upper hole 10 provided with conductive film 13 a. Furthermore, between hole 6 and dug portion 7 a step results. Note that a portion closer to an internal wall surface of dug portion 7 is less exposed to ions and thus less etched. Accordingly, dug portion 7 has bottom 7 a in the form for example of a cone, a hemisphere, or the like.

With reference to FIG. 10, for example, sputtering, CVD or the like is employed to deposit a conductive film 17 a, which will serve as barrier metal 17, on conductive film 15 a to have a thickness of 0.5 nm to 50 nm. Note that conductive film 17 a may be identical in material to conductive film 15 a. Then, a seed film of Cu (not shown) is deposited on conductive film 17 a and a Cu film 19 a is subsequently deposited to fill trench 14 and upper and lower holes 10 and 8. Cu film 19 a is deposited for example by CVD, plating or the like.

With reference to FIG. 1, subsequently on interlayer insulation film 12 excessive conductive films 13 a, 15 a, 17 a and Cu film 19 a are chemically mechanically polished and thus removed to provide barrier metal 13, conductive film 15, barrier metal 17 and CU film 19. Thus the present embodiment's semiconductor device completes.

The present embodiment's semiconductor device includes interlayer insulation film 1, underlying line 5 provided in interlayer insulation film 1, liner film 11 overlying interlayer insulation film 1, and interlayer insulation film 12 overlying liner film 11. Underlying line 5 has lower hole 8 and liner film 11 and interlayer insulation film 12 have upper hole 10 communicating with lower hole 8 and lower hole 8 has diameter d₂ larger than the upper hole's diameter d₁. Furthermore, the semiconductor device includes conductive film 15 provided on an internal wall surface of lower hole 8, barrier metal 13 provided along an internal wall surface of upper hole 10, and Cu film 19 filling upper and lower holes 10 and 8. Conductive film 15 contains a substance identical to a substance of barrier metal 13.

In the present embodiment the semiconductor device is fabricated in a method including the following steps: On interlayer insulation film 1 having underlying line 5 therein liner film 11 and interlayer insulation film 12 are deposited in layers. Upper hole 10 reaching underlying line 5 is provided through liner film 11 and interlayer insulation film 12. Upper hole 10 is internally wet etched to form in underlying line 5 hole 6 having diameter d₂ larger than diameter d₁ of upper hole 10. Conductive film 13 a is provided to cover an internal wall surface of upper hole 10 and only a bottom of hole 6. Conductive film 13 a present at the bottom of hole 6 is physically etched to provide conductive film 15 on an inner wall surface of lower hole 8. Upper and lower holes 10 and 8 are filled with Cu film 19.

In the present embodiment's semiconductor device and its fabrication method conductive film 13 a present at the bottom of hole 6 can physically be etched and thus provided as conductive film 15 on an inner wall surface of lower hole 8. As such, even if lower hole 8 has diameter d₂ larger than diameter d₁ of upper hole 10, lower hole 8 can have reduced voids, and the semiconductor device can be increased in reliability.

In the present embodiment's semiconductor device conductive film 15 further contains a substance identical to a substance of underlying line 5.

In the present embodiment's semiconductor device and its fabrication method conductive film 15 is provided by physically etching conductive film 13 a and underlying line 5 present at a bottom of hole 6.

Thus conductive film 13 a and underlying line 5 can be scattered to provide conductive film 15 having a large thickness on an internal wall surface of lower hole 8. This ensures that conductive film 15 is provided on the internal wall surface of lower hole 8 if underlying line 5 is significantly wet etched.

In the present embodiment's semiconductor device conductive film 15 is not provided in lower hole 8 at bottom 7 a. Thus at the lower hole 8 bottom 7 a Cu film 19 and underlying line 5 are provided with barrier metal 17 alone posed therebetween. As such, reduced electrical resistance can be achieved between Cu film 19 and lower line 5.

In the present embodiment's semiconductor device barrier metal 13 is a film of at least one selected from the group consisting of tantalum nitride, tantalum silicide, tantalum carbide, titanium nitride, titanium silicide, titanium carbide, tungsten nitride, tungsten silicide, tungsten carbide, ruthenium (Ru), and ruthenium oxide.

Thus barrier metal 13 can effectively prevent Cu contained in conductive film 15, CU film 19, and the like from diffusing into liner film 11 and interlayer insulation film 12.

While in the present embodiment in physically etching conducting film 13 a underlying line 5 is also etched, the present invention is not limited thereto, and at least physically etching conductive film 13 a suffices.

Second Embodiment

With reference to FIG. 11, the present embodiment provides a semiconductor device different from that of the first embodiment of the present invention shown in FIG. 1 in that lower hole 8 has dug portion 7 penetrating underlying line 5. Such structure is obtained by performing physical etching in providing conductive film 15 a, as shown in FIG. 8, until underlying line 5 is penetrated.

Other than the above, the semiconductor device's structure and its fabrication method are substantially similar to those of the first embodiment of the present invention shown in FIGS. 1-10. Accordingly, identical components are identically denoted and will not be described.

In the present embodiment the semiconductor device has lower hole 8 penetrating underlying line 5.

In the present embodiment's semiconductor device fabrication method, when conductive film 15 a is provided, physical etching is performed until underlying line 5 is penetrated.

A portion at which the lower hole 8 bottom and underlying line 5 contact each other causes voids more readily than other portions. The present embodiment's semiconductor device and its fabrication method ensure electrical connection between Cu film 19 and underlying line 5 at a portion at which an inner wall of lower hole 8 and underlying line 5 contact each other. As such, if the portion at which the lower hole 8 bottom and underlying line 5 contact each other has voids, the electrical connection between Cu film 19 and underlying line 5 is not affected, and the semiconductor device can thus have high reliability.

Third Embodiment

With reference to FIG. 12, the present embodiment provides a semiconductor device different from that in the first embodiment of the present invention shown in FIG. 1 in that lower hole 8 is located in interlayer insulation film 1 and underlying line 5. Such structure can be obtained in forming upper hole 10, as shown in FIG. 5, by forming upper hole 10 reaching interlayer insulation film 1 and underlying line 5.

Other than the above, the semiconductor device's structure and its fabrication method are substantially similar to those of the first embodiment of the present invention shown in FIGS. 1-10. Accordingly, identical members are identically denoted and will not be described.

In the present embodiment's semiconductor device lower hole 8 is located in interlayer insulation film 1 and underlying line 5.

In the present embodiment's semiconductor fabrication method upper hole 10 is provided to reach underlying line 5 and interlayer insulation film 1.

In the semiconductor device fabrication process when upper hole 10 is provided the hole may be displaced from exactly above underlying line 5, as shown in FIG. 12, as resist is displaced or the like. In the present embodiment's semiconductor device and its fabrication method if upper hole 10 is positionally displaced, a portion at which a conductive film provided in lower hole 8 and underlying line 5 contact each other can be ensured. As a result, the semiconductor device's reliability can be increased and electrical resistance between Cu film 19 and underlying line 5 can be reduced.

While in the first to third embodiments hole 6 has diameter d₂ significantly larger than diameter d₁ of upper hole 10, the present semiconductor device may have hole 6 with diameter d₂ slightly larger than diameter d₁ of upper hole 10, as shown in FIG. 13.

Fourth Embodiment

With reference to FIG. 14, the present embodiment provides a semiconductor device different from that of the first embodiment, as follows: more specifically, Cu film 19 is covered with a liner film 111 deposited on interlayer insulation film 12 and on liner film 111 an interlayer insulation film 112 is deposited. Interlayer insulation film 112 has an upper portion with a trench 114 and in trench 114 and liner film 111 a hole 110 is provided to reach an upper surface 29 of an underlying line 5 a. A barrier metal 113 is provided along an internal wall surface and a bottom of trench 114 and those of hole 110. Trench 114 and hole 110 are filled with a Cu film 119.

Cu film 19, barrier metal 17, and conductive film 15 introduced into upper and lower holes 10 and 8 form a contact 9 a, and Cu film 19 introduced into trench 14 forms underlying line 5 a (a second line). Furthermore, Cu film 119 (a connection layer) filling hole 110 (a hole for the second line) forms a contact 9 b, and Cu film 119 filling trench 114 forms a line 5 b. In other words, in the present embodiment, underlying line 5 followed by line 5 a and then line 5 b are sequentially deposited in layers each with insulation film posed therebetween, and underlying line 5 and line 5 a are electrically connected by contact 9 a and lines 5 a and 5 b are electrically connected by contact 9 b.

Note that contacts 9 a and 9 b are structurally different. Of upper and lower holes 10 and 8 having contact 9 a therein, lower hole 8 is located in underlying line 5. By contrast, hole 110 having contact 9 b therein does not extend into line 5 a and instead stops at upper surface 29 of line 5 a. Furthermore, hole 110 having contact 9 b therein has a diameter d₁₀₁ larger than diameter d₁ of hole 10 having contact 9 a therein.

The present embodiment's semiconductor device includes line 5 a, hole 110 reaching line 5 a at the top, and Cu film 119 filling hole 110. Hole 110 does not extend into line 5 a.

The present embodiment's semiconductor device is effective as follows: a contact large in diameter contacts an underlying line over a large area. As such, it provides a small current density and hardly provides a point initially causing voids in comparison with other contacts. As such, if the contact large in diameter is modified to have such a simple structure as contact 9 b, the semiconductor device can still be ensured in reliability. For contact 9 b, it is unnecessary to etch line 5 a and form a lower hole communicating with hole 110, and the semiconductor device can be fabricated in a simplified process and hence at reduced cost.

Furthermore in the present embodiment's semiconductor device hole 110 can have diameter d₁₀₁ larger than diameter d₁ of upper hole 10. As such, if contacts 9 a and 9 b pass a current of a single magnitude, contact 9 b providing a smaller current density can be simplified in structure.

Furthermore in the present embodiment's semiconductor device hole 110 overlies upper hole 10. Normally, an overlying contact provides a smaller current density than an underlying contact, and contact 9 b provided in the overlying hole 110 can be simplified in structure.

Note that the hole may not be filled with Cu layer 19 and 119 and instead be filled with a layer of silver (Ag), a layer of an alloy containing Cu and Ag as a main component, or the like.

Fifth Embodiment

With reference to FIG. 15, the present embodiment provides a semiconductor device including a large number of lines 35 a-35 f and contacts 39 a-39 e electrically connecting lines 35 a-35 f. On line 35 a, line 35 b is deposited, followed by line 35 c, 35 d, 35 e, 35 f, sequentially in layers each with an insulation layer posed therebetween. Lines 35 a and 35 b are electrically connected by contact 39 a. Lines 35 b and 35 c are electrically connected by contact 39 b. Lines 35 c and 35 d are electrically connected by contact 39 c. Lines 35 d and 35 e are electrically connected by contact 39 d. Line 35 e and 35 f are electrically connected by contact 39 e.

Contacts 39 a-39 e each have a diameter A or a diameter C. Contacts 39 a-39 c each have diameter A. Contacts 39 d and 39 e each have diameter C. Diameter C is larger than diameter A.

In the present embodiment, a contact substantially similar in geometry to the FIG. 14 contact 9 a and a contact substantially similar in geometry to the FIG. 14 contact 9 b are mixed together. More specifically, of contacts 39 a-39 e, contacts 39 a-39 c having diameter A are each substantially similar in geometry to contact 9 a, and contacts 39 d and 39 e having diameter C are each substantially similar in geometry to contact 9 b.

Furthermore, with reference to FIG. 16, contacts 39 a-39 e each have diameter A, a diameter B, or diameter C. Contacts 39 a and 39 b each have diameter A. Contact 39 c has diameter B. Contacts 39 d and 39 each have diameter C. Diameter C is larger than diameter B, and diameter B is larger than diameter A.

In the FIG. 16 structure, of contacts 39 a-39 e, contacts 39 a-39 c having diameters A and B are each substantially similar in geometry to contact 9 a, and contacts 39 d and 39 e having diameter C are each substantially similar in geometry to contact 9 b.

Furthermore, of contacts 39 a-39 e, contacts 39 a and 39 b having diameter A may each be substantially similar in geometry to contact 9 a, and contacts 39 c-39 e having diameters B and C may each be substantially similar in geometry to contact 9 b.

Except for the above arrangement, the semiconductor device has a structure substantially similar to that of the FIG. 15 semiconductor device. Accordingly, identical members are identically denoted and will not be described.

As provided in the present embodiment's semiconductor device, if a large number of contacts 39 a-39 e are provided, each contact having a relatively small diameter can be formed in a geometry substantially similar to contact 9 a and each contact having a relatively large diameter can be formed in a geometry substantially similar to contact 9 b so that as well as in the fifth embodiment, the semiconductor device can be ensured in reliability and also be fabricated at reduced cost.

While FIG. 15 shows contact 39 a-39 c having diameter A that have a geometry substantially similar to contact 9 a, of the contacts having diameter A the lowermost layer's contact 39 a alone may be formed to have a geometry substantially similar to contact 9 b.

Furthermore while in the present embodiment a contact having a relatively small diameter underlies that having a relatively large diameter, they may be provided at any position.

Sixth Embodiment

With reference to FIG. 17, contacts 39 a-39 e have diameter A or C. Contacts 39 a-39 c each have diameter A and contacts 39 d and 39 e each have diameter C. Diameter C is larger than diameter A.

In the present embodiment contacts 39 a and 39 b each passes a current larger in amount than that contact 39 c does. As such, even though contacts 39 a-39 c have the same diameter A, contacts 39 a and 39 b each provide a current density larger than contact 39 c. Similarly, as contact 39 d passes a current larger in amount than contact 39 e, contact 39 d provides a current density larger than contact 39 e despite that contacts 39 d and 39 e have the same diameter C.

Accordingly, of contacts 39 a-39 e, contacts 39 a, 39 b and 39 d providing a relatively large current density are each adapted to be substantially similar in geometry to contact 9 a, whereas contacts 39 c and 39 e providing a relatively small current density are each adapted to be substantially similar in geometry to contact 9 b.

Except for the above arrangement, the semiconductor device is substantially similar to that shown in FIG. 15, and identical members are identically denoted and will not be described.

In a semiconductor device having a large number of lines a current density varies for each contact, and for a contact with a large current density voids are caused more readily than for a contact with a small current density. As such, a line readily breaks. As such if the contact with relatively small current density is formed to have such a simple structure as contact 9 b, the semiconductor device is still ensured in reliability. Thus for the contact with relatively small current density a simplified fabrication process can be adopted, and the semiconductor device can be fabricated at reduced cost.

FIRST EXAMPLE

Hereinafter one example of the present invention will be described.

In the present example, a conventional semiconductor device and the present semiconductor device were compared in reliability. More specifically, a conventional semiconductor device having a via hole formed without etching an underlying line and the present semiconductor device shown in FIG. 1 were compared in longevity. FIG. 8 shows a result thereof. For the conventional semiconductor device, a group of black dots and that of white dots, as shown in FIG. 18, were compared in longevity. A square indicates the present semiconductor device.

As shown in FIG. 18, approximately 50-60% of the entire samples of the conventional semiconductor device had electromigration (EM), stress migration (SM) or similar defect within 10^(n+1) hours, and were found to be defective products. In contrast, it can be seen that the present semiconductor device hardly provided defective product even after 10^(n+1) hours. It can be understood therefrom that the present semiconductor device can alleviate thermal stress and a current otherwise concentrated at a portion at which a surface of underlying line 5 and a bottom of a conductive film provided in lower hole 8 contact each other, and that the semiconductor device can be increased in reliability.

Although the present invention has been described and illustrated in detail, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, the spirit and scope of the present invention being limited only by the terms of the appended claims. 

1. A method of fabricating a semiconductor device, comprising: forming an lower wiring layer including a first insulating film and a Cu wiring which is formed in said first insulating film and includes copper; depositing a second insulating film on said first insulating film and said Cu wiring; depositing a third insulating film on said second insulating film; forming an upper hole in said second and third insulation films, said upper hole reaching said Cu wiring; performing a wet treatment to the upper hole to remove a residue of the second insulation film; after the performing the wet treatment, depositing a first barrier metal covering an inner wall surface of said upper hole; physically etching said first barrier metal and said Cu wiring which are present below said upper hole to form a lower hole in said Cu wiring, said lower hole narrowing gradually from an upper portion of said lower hole to a lower portion of said lower hole, said upper hole formed over said lower hole; depositing a second barrier metal along an inner wall surface of the first barrier metal and an inner wall surface of the lower hole; and depositing a conductive film containing copper and filling said upper and lower holes, the conductive film formed on the second barrier metal.
 2. The method according to claim 1, wherein said first barrier metal is a compound of a nitride with a metal and wherein a lower end of the first barrier metal is higher than a lower end of the second barrier metal.
 3. The method according to claim 2, wherein said first barrier metal is a film of at least one selected from a group consisting of tantalum nitride, titanium nitride, and tungsten nitride, and wherein second barrier metal is tantalum.
 4. The method according to claim 3, further comprising: before depositing said first barrier metal, after forming said upper hole, forming a trench in said third insulation film, a lower portion of said trench communicating with an upper portion of said upper hole; and after depositing said conductive film, forming an upper wiring layer; wherein when depositing said first barrier metal, depositing said first barrier metal along a bottom surface of said trench and a side wall of said trench, wherein when depositing said conductive film, filling said conductive film in said trench to form a predetermined wiring which is formed by said conductive film and said first barrier metal in said trench and said upper hole, wherein said upper wiring layer includes a fourth insulation film formed on said third insulation film and said predetermined wiring, a fifth insulation film formed on said fourth insulation film, a hole which exposes an upper surface of said predetermined wiring and is formed in said fourth insulation film and said fifth insulation film, a third barrier metal formed along an inner wall surface of said hole and a bottom of said hole, and a copper conductor which is formed in said hole and is filling in said hole, wherein said third barrier metal formed along said bottom of said hole is in contacts with said upper surface of said predetermined wiring and is a flat portion, and wherein said hole is larger in diameter than said upper hole.
 5. The method according to claim 3, wherein when physically etching said first barrier metal and said Cu wiring, physically etching said first insulation film, said first barrier metal, and said Cu wiring which are present below said upper hole to form said lower hole in said Cu wiring and said first insulation film.
 6. The method according to claim 3, wherein said lower hole is a cone shape or a hemisphere shape.
 7. The method according to claim 3, wherein a depth of said lower hole is equal to or more than 30 nm.
 8. The method according to claim 3, further comprising: said physically etching said first barrier metal and said Cu wiring, depositing a predetermined conductive film along an inner wall surface of said first barrier metal in said upper hole and along an inner wall surface of said lower hole, wherein said predetermined conductive film includes Cu and a material of the first barrier metal.
 9. The method according to claim 3, wherein the wet treatment is wet etching an interior of the upper hole to form a predetermined hole in the Cu wiring, the Cu wiring communicating with the upper hole, and wherein the predetermined hole is arranged between the upper hole and the lower hole.
 10. A method of fabricating a semiconductor device, comprising: preparing a Cu wiring containing copper formed in a first insulating film; forming a second insulating film on said first insulating film and said Cu wiring; forming a third insulating film on said second insulating film; forming a first hole in said second and third insulation films, said first hole having a bottom and exposing said Cu wiring; performing a wet treatment to the first hole to remove a residue of the second insulation film; after the performing the wet treatment, forming a first barrier metal covering an inner wall surface of said first hole in said second and third insulating films and the bottom of said first hole; performing a physical etching to said first barrier metal and said Cu wiring below said first barrier metal which are arranged below said first hole in order to form a recess in said Cu wiring; and depositing a second barrier metal along an inner wall surface of the first barrier metal and an inner wall surface of the recess; and forming a conductive film containing copper and filling said first hole and said recess of said Cu wiring, the conductive film formed on the second barrier metal.
 11. The method according to claim 10, wherein said first barrier metal is a compound of a nitride with a metal.
 12. The method according to claim 11, wherein said first barrier metal is a film of at least one selected from a group consisting of tantalum nitride, titanium nitride, and tungsten nitride, and wherein second barrier metal is tantalum.
 13. The method according to claim 12, further comprising: before forming said first barrier metal, after forming said first hole, forming a trench in said third insulation film, a lower portion of said trench communicating with an upper portion of said first hole; and after forming said conductive film, forming an upper wiring layer; wherein when forming said first barrier metal, depositing said first barrier metal along a bottom surface of said trench and a side wall of said trench, wherein when forming said conductive film, filling said conductive film in said trench to form a predetermined wiring which is formed by said conductive film and said first barrier metal in said trench and said upper hole, wherein said upper wiring layer includes a fourth insulation film formed on said third insulation film and said predetermined wiring, a fifth insulation film formed on said fourth insulation film, a hole which exposes an upper surface of said predetermined wiring and is formed in said fourth insulation film and said fifth insulation film, a third barrier metal formed along an inner wall surface of said hole and a bottom of said hole, and a copper conductor which is formed in said hole and is filling in said hole, wherein said third barrier metal formed along said bottom of said hole is in contacts with said upper surface of said predetermined wiring and is a flat portion, and wherein said hole is larger in diameter than said first hole.
 14. The method according to claim 12, wherein when said performing said physically etching said first barrier metal and said Cu wiring, physically etching said first insulation film, said first barrier metal, and said Cu wiring which are present below said first hole to form said recess in said Cu wiring and said first insulation film.
 15. The method according to claim 12, wherein said recess is a cone shape or a hemisphere shape.
 16. The method according to claim 12, wherein a depth of said recess is equal to or more than 30 nm.
 17. The method according to claim 12, wherein a diameter of said recess is smaller than a diameter of said first hole.
 18. The method according to claim 10, further comprising: said performing a physically etching to said first barrier metal and said Cu wiring, forming a predetermined conductive film over said first barrier metal in said first hole and along an inner wall surface of said recess of said Cu wiring, wherein said predetermined conductive film includes Cu and a material of the first barrier metal.
 19. The method according to claim 10, wherein the wet treatment is wet etching an interior of the upper hole to form a predetermined hole in the Cu wiring, the Cu wiring communicating with the upper hole, and wherein the predetermined hole is arranged between the first hole and the recess.
 20. The method according to claim 10, wherein a lower end of the first barrier metal is higher than a lower end of the second barrier metal. 